THERMAL AND CHEMICAL UTILIZATION OF CARBONACEOUS MATERIALS, IN PARTICULAR FOR EMISSION-FREE GENERATION OF ENERGY

• US 20120238645A1
• Filed: 11/19/2010
• Published: 09/20/2012
• Est. Priority Date: 11/20/2009
• Status: Active Grant

• Current Assignee: RV Lizenz AG
• Original Assignee: RV Lizenz AG
• Inventors: Rüdlinger, Mikael
• Granted Patent: US 10,450,520 B2
• Time in Patent Office: Days
• US Class Current: 518/700
• CPC Class Codes: C07C 29/151 with hydrogen or hydrogen-containing gases
• CPC Class Codes: C10G 2/30 from carbon monoxide with hydrogen
• CPC Class Codes: C10G 2300/1011 Biomass
• CPC Class Codes: C10G 2300/1022 Fischer-Tropsch products
• CPC Class Codes: C10G 2300/4037 In-situ processes
• CPC Class Codes: C10G 2300/4081 Recycling aspects
• CPC Class Codes: C10J 2300/094 Char
• CPC Class Codes: C10J 2300/0959 Oxygen
• CPC Class Codes: C10J 2300/0966 Hydrogen
• CPC Class Codes: C10J 2300/0969 Carbon dioxide
• CPC Class Codes: C10J 2300/1606 Combustion processes
• CPC Class Codes: C10J 2300/1659 to liquid hydrocarbons Fischer-Tropsch process C10G2/00
• CPC Class Codes: C10J 2300/1665 to alcohols, e.g. methanol or ethanol preparation of alcohols in general C07C29/00
• CPC Class Codes: C10J 2300/1671 with the production of electricity
• CPC Class Codes: C10J 2300/1675 making use of a steam turbine
• CPC Class Codes: C10J 2300/1693 with storage facilities for intermediate, feed and/or product
• CPC Class Codes: C10J 2300/1807 Recycle loops, e.g. gas, solids, heating medium, water
• CPC Class Codes: C10J 2300/1823 for synthesis gas
• CPC Class Codes: C10J 2300/1846 Partial oxidation, i.e. injection of air or oxygen only
• CPC Class Codes: C10J 2300/1884 with one stream being synthesis gas
• CPC Class Codes: C10J 2300/1892 : with one stream being water/steam
• CPC Class Codes: C10J 3/20 : Apparatus; Plants
• CPC Class Codes: C10J 3/40 : Movable grates
• CPC Class Codes: C10J 3/58 : combined with pre-distillation of the fuel
• CPC Class Codes: C10J 3/66 : by introducing them into the gasification zone
• CPC Class Codes: F01K 13/00 : General layout or general methods of operation of complete plants
• CPC Class Codes: F02C 3/28 : using a separate gas producer for gasifying the fuel before combustion
• CPC Class Codes: F23C 2900/9901 : Combustion process using hydrogen, hydrogen peroxide water or brown gas as fuel
• CPC Class Codes: Y02E 20/12 : Heat utilisation in combustion or incineration of waste
• CPC Class Codes: Y02E 20/32 : Direct CO2 mitigation
• CPC Class Codes: Y02E 50/10 : Biofuels, e.g. bio-diesel
• CPC Class Codes: Y02P 30/20 : using bio-feedstock

Abstract

A process for the generation of energy and/or hydrocarbons and other products utilizing carbonaceous materials. In a first process stage (P1) the carbonaceous materials are supplied and are pyrolysed, wherein pyrolysis coke (M21) and pyrolysis gas (M22) are formed. In a second process stage (P2), the pyrolysis coke (M21) from the first process stage (P1) is gasified, wherein synthesis gas (M24) is formed, and slag and other residues (M91, M92, M93, M94) are removed. In a third process stage (P3), the synthesis gas (M24) from the second process stage (P2) is converted into hydrocarbons and/or other solid, liquid, and/or gaseous products (M60), which are discharged. The three process stages (P1, P2, P3) form a closed cycle. Surplus gas (M25) from the third process stage (P3) is passed as recycle gas into the first process stage (P1), and/or the second process stage (P2), and pyrolysis gas (M22) from the first process stage (P1) is passed into the second process stage (P2), and/or the third process stage (P3),

Claims

1. A process for the emission-free generation of energy and/or hydrocarbons and other products by utilization of carbonaceous materials, in which in a first process stage the carbonaceous materials are supplied and pyrolysed, wherein pyrolysis coke and pyrolysis gas are formed;

in a second process stage, the pyrolysis coke from the first process stage is gasified, wherein synthesis gas is formed, and slag and other residues are removed; and

in a third process stage, the synthesis gas from the second process stage is converted into hydrocarbons and/or other solid, liquid and/or gaseous products, which are discharged;

wherein the three process stages form a closed cycle, surplus gas from the third process stage is passed as recycle gas into the first process stage and/or the second process stage, and the pyrolysis gas of the first process stage is passed into the second process stage and/or the third process stage.

2. The process according to claim 1, wherein hydrogen is supplied in at least one said process stage.

3. The process according to claim 1, wherein carbon dioxide is supplied in at least one said process stage.

4. The process according to claim 1, wherein there is a pressure drop along the cycle.

5. The process according to claim 1, wherein heat energy for the pyrolysis reactions in the first process stage is provided, at least in part by returning a part of hot synthesis gas from the second process stage into the first process stage, and/or by partial oxidation of the carbonaceous starting material and the resultant pyrolysis coke.

6. The process according to claim 1, wherein the first process stage is carried out at a temperature between 300 and 800°

C.

7. The process according to claim 1, wherein for the gasification reaction in the second process stage oxygen and/or steam and/or carbon dioxide is used as a gasification agent.

8. The process according to claim 1, wherein in the second process stage, the thermal energy required for the gasification reaction is supplied, at least in part from outside;

and/or is generated by oxidizing a part of the pyrolysis coke with an oxidizing agent.

9. The process according to claim 1, wherein the second process stage is carried out at a temperature between 600 and 1600°

C.

10. The process according to claim 1, wherein the first process stage and/or the second process stage is carried out at a pressure between 1 and 60 bar.

11. The process according to claim 1, wherein the first process stage and the second process stage are carried out in a pressure reactor and wherein the same pressure reactor is used to carry out both the first and the second process stages.

12. The process according to claim 1, wherein the conversion in the third process stage is carried out using a Fischer-Tropsch synthesis or a liquid-phase methanol synthesis.

13. The process according to claim 1, wherein electrical and/or mechanical energy is generated by oxidation of the hydrocarbons and other solid, liquid, and/or gaseous products of the third process stage, to a oxidation gas, said oxidation gas essentially consisting essentially of carbon dioxide and water.

14. The process according to claim 13, wherein pure oxygen is used as an oxidizing agent.

15. The process according to claim 13, wherein water is condensed out and/or separated from the oxidation gas.

16. The process according to claim 13, wherein at least a part of the oxidation gas is fed back into at least one of the first process stage, the second process stage and the third process stage of the generation process.

17. The process according to claim 1, wherein electrical and/or mechanical energy is generated by cooling the synthesis gas in a heat exchanger, wherein superheated steam and/or another hot gas are formed, from which electrical and/or mechanical energy is generated using a heat engine.

34. The process according to claim 2, wherein the hydrogen is supplied in the third process stage.

35. The process according to claim 3, wherein the carbon dioxide is supplied in the first process stage or the second process stage.

36. The process according to claim 6, wherein the first process stage is carried out at a temperature between 450 and 700°

C.

37. The process according to claim 6, wherein the first process stage is carried out at a temperature between 500 and 600°

C.

38. The process according to claim 8, wherein the thermal energy required for the gasification reaction in the second process stage is supplied by heating devices and/or heat exchangers.

39. The process according to claim 8, wherein the thermal energy required for the gasification reaction is generated by oxidizing a part of the pyrolysis coke using oxygen as the oxidizing agent.

40. The process according to claim 9, wherein the second process stage is carried out at a temperature between 700 and 1400°

C.

41. The process according to claim 9, wherein the second process stage is carried out at a temperature between 850 and 1000°

C.

42. The process according to claim 10, wherein the pressure is between 5 bar and 25 bar.

43. The process according to claim 10, wherein the pressure is between 10 bar and 15 bar.

44. The process according to claim 17, wherein the heat engine is a steam turbine.

18. A facility for emission free generation of energy and/or hydrocarbons and/or other products by utilizing carbonaceous materials, with a utilization installation comprising a utilization unit with a first subunit for carrying out a pyrolysis of the carbonaceous materials to form pyrolysis coke and pyrolysis gas;

a second subunit for carrying out a gasification of the pyrolysis coke to form synthesis gas and residues; and

a third subunit for carrying out a conversion of the synthesis gas into hydrocarbons and/or other solid, liquid and/or gaseous products;

wherein all three subunits of the utilization unit are pressure-tightly closed and form an essentially closed cycle;

a transport pipe for the pyrolysis gas connects the first subunit pressure-tightly to the second subunit and/or to the third subunit;

a transport pipe for the synthesis gas connects the second subunit pressure-tightly to the third subunit and/or to the first subunit; and

a transport pipe for the recycle gas connects the third subunit pressure-tightly to the first subunit and/or to the second subunit.

19. The facility according to claim 18, wherein at least one compressor is arranged along at least one of said transport pipes of the utilization unit.

20. The facility according to claim 18, wherein the subunits of the utilization unit each comprise one or more pressure reactors.

21. The facility according to claim 18, wherein the first subunit and the second subunit of the utilization unit comprise a shared pressure reactor.

22. The facility according to claim 18, wherein the third subunit of the utilization unit comprises a Fischer-Tropsch synthesis stage, and/or a liquid-phase methanol synthesis stage.

23. The facility according to claim 18, wherein the facility comprises an energy installation that is arranged for generating at least one of electrical energy, mechanical energy and thermal energy by using hydrocarbons and/or other products from the utilization installation as fuels.

24. The facility according to claim 23, wherein the energy installation is provided with a drive device for generating electrical and/or mechanical energy from the fuels, wherein said drive device obtains the energy necessary for operation from the oxidation of the fuels to an oxidation gas consisting essentially of carbon dioxide and water, and comprises a device for the compression and/or condensation of the oxidation gas.

25. The facility according to claim 24, wherein the drive device of the energy installation is operable with pure oxygen as an oxidizing agent.

26. The facility according to claim 24, wherein the drive device of the energy installation comprises a heat exchanger for cooling down a stream of the oxidation gas, upstream and/or downstream of the device for the compression and/or condensation of the oxidation gas.

27. The facility according to claim 24, wherein the drive device of the energy installation comprises a device for condensation and/or separation of water from the oxidation gas.

28. The facility according to claim 24, wherein the drive device of the energy installation is provided with a storage for collecting the oxidation gas, or the residual gas after compression and/or condensation, respectively, of the oxidation gas.

29. The facility according to claim 24, wherein the drive device of the energy installation is a combustion engine, with at least one combustion chamber for combustion of liquid or gaseous fuel with oxygen, with means for converting resulting gas pressure or gas volume into mechanical work, with a feed device for introducing oxygen into the combustion chamber, and with a venting device for removing the oxidation gas from the combustion chamber.

30. The facility according to claim 29, wherein the drive device of the energy installation is provided with a feed device for introducing water and/or steam into the combustion chamber, and/or into a stream of the oxidation gas after exit from the combustion chamber.

31. The facility according to claim 18, wherein the utilization installation comprises an energy unit for generating electrical and/or mechanical energy, with at least one drive device for generating electrical and/or mechanical energy from steam and/or other hot gases that have been generated or superheated in the utilization unit.

32. The facility according to claim 31, wherein the energy unit of the utilization installation comprises a drive device for generating electrical and/or mechanical energy from steam or other hot gases that have been generated or superheated in the utilization unit;

and in that in a cycle of the utilization unit at least one heat exchanger is provided for heating steam and/or other gases, and/or for generating steam.

33. The facility according to claim 18, wherein the facility comprises an installation for the production of hydrogen, and means for supplying the hydrogen into the utilization unit.